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By G. Castillo, J. Mortensen

"INTRODUCTION Molybdenite is typically produced as a co-product in the copper ore flotation process. At the Rio Tinto Kennecott Concentrator (RTKC) in Copperton, Utah, the molybdenite is initially floated with copper sulfides and other value minerals producing a Cu-Mo concentrate. This is then separated in the molybdenum plant by depressing copper sulfides and pyrite and floating only molybdenite. The molybdenum plant in RTKC comprises the rougher circuit and several stages of cleaning to achieve a certain grade requirement of Mo. The rougher circuit is where the first stage of separation occurs. Cu sulfides and pyrite are depressed in the rougher circuit by adding NaSH under nitrogen and in the cleaner circuit by adding NaSH under air. The depression of Cu sulfides (and pyrite) by NaSH is related to the redox activity1. It is important therefore to maintain a reducing potential in the circuit in order to achieve effective Cu-Mo separation. If the rougher circuit is under air, like RTKC’s molybdenum cleaner circuits, it is harder to maintain the target redox potential because NaSH oxidizes rapidly in the presence of air thereby increasing NaSH consumption significantly. CU-MO SEPARATION AND ROLE OF PULP POTENTIAL The collector adsorption on copper sulfide minerals is through an electrochemical mechanism2. The collector changes the surface chemistry of the Cu mineral allowing it to float. Molybdenite, or MoS2, on the other hand, floats readily in the presence of a frother as it is naturally hydrophobic. Usually, hydrocarbon oil extenders such as diesel or burner oil are added to enhance Mo recovery. In order to effectively separate Cu from Mo, the collector complex on the copper surface needs to be destabilized or desorbed using a reducing agent such as NaSH or Nokes. As long as the circuit is under highly reducing conditions, the collector remains detached from the sulfide mineral surface allowing Cu sulfide depression. Therefore, it is important to measure the oxidation-reduction potential (ORP) continually and maintain the reducing condition with addition of NaSH. For a given collector each mineral will have a characteristic potential or electrochemical window for flotation to occur3, therefore, it is necessary to reduce the potential outside of this window in order to effectively separate Cu and Fe sulfides from MoS2 minerals2. In RTKC plant, the target reducing condition is between -450 to -550 mV to effectively destabilize the collector and depress Cu and Fe minerals. Typically the dosage of NaSH used in the molybdenum plant could range from 6 to 30 gallons/min (gpm). The high dosage of NaSH could pose risk of H2S exposure. RTKC wanted to evaluate alternatives to NaSH in order to reduce its consumption and minimize risk of H2S gas generation."

Jan 1, 2016

By H. J. B. Couto, J. G. S. Puelles, M. L. Torem, R. H. Rojas, A. G. Merma

Understanding the limits of fine particle flotation is fundamental to achieving a significant and selective separation. Conventional flotation processes are not suitable to treat these particles because of their low collision efficiency. This problem can be overcome by decreasing the bubble size or by increasing the apparent particle size. However it is worth noting that the use of small bubbles or micro bubbles also involves some disadvantages such as their low momentum resulting in a slower process comparing with conventional flotation. Electroflotation is an attractive alternative for treating fine particles with small bubbles less than 100 µm, generated by the electrolysis of water. In this sense, this study assesses the effect of current density and pH on bubble size in a binary electroflotation cell. An increase in the bubble generation rate was reported with an increase in current density. In addition, at acid pH values, the size of oxygen bubbles increased and conversely decreased at basic pH values; this may be due to the electrostatic attraction between the oxygen bubbles and the anode resulting in a greater nucleation time. An opposite trend was observed with the hydrogen bubbles. These results are in agreement with their electrokinetic studies, which reported that at acid conditions the bubble surface may be positively charged for both the hydrogen and the oxygen bubbles. Finally the bubble size was slightly affected by the electrolyte concentration, resulting in smaller diameter bubbles at higher concentrations.

Jan 1, 2016

By Paolo Toscano, Dave Hall

"This paper discusses the project history, process design and layout of the Rainy River Gold Project mill. The circuit consists of a 55 x 83 primary crusher, 15 MW SAG mill and 15 MW ball mill. Both mills are twin pinion with LSS and VFD drives. A pebble crusher is located in the process plant with bypass and stockpile options. Gravity concentration followed by 30 hours of leach residence, carousel CIP, carbon recovery, cyanide destruction and tails disposal in a 1,428 hectare tailings management area (TMA).The Rainy River Gold Project is located approximately 65 km northwest of Fort Frances in north western Ontario. The project is scheduled to be commissioned and reach commercial production in mid-2017. Expected cost is $US877M and is comprised of an open pit mine, process plant, tailings management area and supporting infrastructure. The process plant is designed to produce gold/silver Dore’ bars.The project has been developed on the following timeline:• 1967 – First exploration• 1994 – 17 zone discovered• 2004 – 433 Zone discovered• 2005 – Rainy River Resources Ltd. purchases property • 2006 - ODM zone discovered• 2007 - Cap Zone discovered• 2008 - First NI-43-101 Resource completed• 2012 - PEA completed & Intrepid Zone discovered• 2013 - New Gold acquires Rainy River Resources• 2014 - Updated feasibility study completed & Environmental Assessment report submitted• 2015 - Detailed Engineering >95% complete, EA approved and construction commencesThe property is accessed by provincial highway 600 and is within 17 km of 230 kV power line and railway sidings. Key project criteria are summarized as follows:"

Jan 1, 2016

By P. Zhang, K. Liu, L. Ou

"The strength and mechanism of Portland cement prepared from stone coal vanadium slag were studied in this paper. Initially, the slag was used as silicon raw materials to prepare clinker. By blending the prepared clinker with gypsum, waste, and fly ash, a series of different grades cement got well prepared. All of performances of the cement were up to the requirements of China’s national standard. The hydration products and microstructure of cement were identified and analyzed by X-ray diffraction and scanning electron microscopy. With the comparison of cement hydration characteristics at different ages, the strength formation mechanism of cement was clarified. The experimental results suggested that adding the fine materials (mainly waste and fly ash) to replace part of clinker would accelerate cement hydration, as it provided additional surfaces for the nucleation and growth of hydration products. And the hydration products were similar to ordinary Portland cement, mainly containing the amorphous calcium silicate hydrates (C-S-H), acicular ettringite (AFt) and portlandite (CH). With hydration time increasing, the hydration products continuously covered the cement particles, resulting in a thicker surface layer. As a result, it gradually condensed into a dense structure block with small pores and smooth surfaces, which led to higher strength. In conclusion, using the vanadium slag to prepare Portland cement can realize the utilization of solid mineral wastes, which will bring huge ecological and economic benefits.INTRODUCTIONWith the development of China’s mining industry, more and more mineral waste residue is discharged every year. These solid wastes cause varieties of resources and environmental problems on people’s living area. While at the same time, the demands of cement are increasing with the remarkable development of the construction industry. Thus, in recent years, utilization of proper solid waste to prepare cement has become an efficient way to deal with the solid mineral wastes problems (Boncukcuoglu, Kocakeri?M, & Tosunoglu, 2002; Simatupang, Hanafi, Purwasasmita, Imran, & Pane, 2012; Tsakiridis, Papadimitriou, Tsivilis, & Koroneos, 2008; Yun, Yong, Choi, Lee, & Lachemi, 2009)."

Jan 1, 2016

By Yongjie Bu, Wei Sun, Zhiyong Gao, Yuehua Hu, Hongbiao Tao, Runqing Liu, Central South University

"The flotation behavior of O-isopropyl-N-ethyl thionocarbamate (IPETC) and pH for chalcopyrite and galena was studied through pure mineral test, adsorption quantity determination, solution chemistry calculation and Materials Studio simulation. The results show that the recovery differential value of chalcopyrite and galena is about 20% when pH of the pulp 9.5 and IPETC is 7×10-4 mol/L, the flotability differences of the two minerals is significant. There is competitive adsorption between OH? and IPETC on mineral surfaces, it lead to galena flotability is lower than chalcopyrite flotability. IPETC can remove the hydration layer on mineral surface and adsorb on active sites for collector adsorption, minerals have a better hydrophobicity.INTRODUCTIONCopper and lead are two of the most widely used metals in industrial and living, their applications include building construction, various metal alloys, heat and electricity, machine manufacturing (Zhang et al., 2014). Chalcopyrite and galena are the major source of copper and lead, normally they associated with each other. With the growing use of these resources, high grade and dissemination large particle sizes minerals are less and less, the use of low grade and complex dissemination minerals have to be paid more attention (Chen, Ye, & Li, 2010; Liu, Sun, Hu, & Wang, 2009). As the special properties and complex composition of copper-lead sulfide ore, flotation separation of chalcopyrite from galena effective is a research emphasis and difficulty point in mineral processing (Bruckard, Sparrow, & Woodcock, 2011).In the separation process of chalcopyrite and galena, it is rather important to choose effective collector (Huang, Wang, & Liu, 2014). Enlarging and using the two mineral flotability will be a good basis and start in flotation (Reyes-Bozo et al., 2014). Qin et al. (2013) made a great deal of research on flotation separation of copper/lead concentrate, collector O-isopropyl-N-ethyl thionocarbamate (IPETC), butyl xanthate (BX) and ammonium dibutyl dithiophosphate (ADTP) were investigated, BX and ADTP floated both chalcopyrite and galena well, specific adsorption appeared in the surface of mineral, the problem was the collectors were not selective enough, however IPETC showed better selective."

Jan 1, 2016

By B. Berhe, R. D. Lawrence, J. Hinzer

"The fortunes of mining companies and their implied value are tied to cycles - both economic and commodity – within which they operate. Hence the determination of appropriate future metal prices is one of the most critical factors faced by mineral valuators especially for advanced projects. Price, and hence revenue, is usually the most sensitive input to the valuation model. Empirical studies of past forecasts show that the success rate for commodity price forecasting is very poor. This paper explores various approaches and comments on their strengths and weaknesses. We conclude that careful evaluation of long-term metal prices is a key element and is hardly a luxury that can be left to simple averages or rules of thumb. INTRODUCTION Discounted Cash Flow (""DCF"") analysis, is well suited for the valuation of advanced mineral development assets, for which there are identified mineral resources and some form of economic assessment (Pre-Feasibility or Feasibility Study). The DCF method is also the most commonly used method for determining value for such assets. It provides a means of relating the magnitude of expected future cash flows from profits (or losses) to the magnitude of the initial cash flow (investment) needed for capital expenditures to purchase or to develop an asset for commercial production. The method proves useful in making investment decisions as it allows for the quantification of the Net Present Value (“NPV”), as well as the Internal Rate of Return (IRR) and Payback Period on initial investment capital. Valuation by its very nature is a forward-looking exercise. The DCF method attempts to estimate the NPV of expected future cash flows, by selecting factors that will likely affect future cash flow based on informed analysis. One of the most critical and sensitive factors is the determination of appropriate future commodity prices. “The variables that have the greatest impact on a DCF evaluation are the reserves, the metal prices, and the discount rate.”1 The determination of future commodity prices for valuation purpose or during M&A negotiations is a hotly contested issue. There are a number of analysts, institutions and specialized commercial data suppliers that provide both short and long-term commodities price forecasts. Also, the use of an aggregated mean for all available forecasts, or consensus forecasted prices for valuation purposes is not uncommon. The methods used in making forecasts for each forecaster may vary and in many cases may not be publically disclosed. Nonetheless, the aggregated mean of all forecasted commodity prices of reputed institutions is usually taken to “represent the market’s view of likely future commodity prices.”"

Jan 1, 2016

By Ausenco Engineering Canada

"This paper demonstrates the selection of grinding circuit technology for a number of recent projects including discussion of the key drivers and the role of energy efficiency. Decreasing head grades combined with a strong and sustained increase in operating costs has forced miners to examine increased project size, increased equipment capacity and efficiency improvements in order to reduce their unit operating costs and improve overall project economics. Comminution energy consumption, safety and capital cost considerations play a critical role in the success of projects. This paper presents some key guidelines for a successful and cost effective comminution circuit design and includes a case study on three projects, outlining the issues and the drivers which led to the ultimate circuit selection and the critical role that energy efficiency played.INTRODUCTIONComminution circuits for minerals processing are selected based on their suitability and efficiency in reducing run-of-mine ore to the desired feed size for the downstream process. The input material (ore) properties and downstream process requirements are the key determinants and there are standard approaches for each circumstance.The minerals processing industry has been a fast adaptor of efficiency improvements based on increasing capacity of equipment (e.g. trucks, crushers, mills, pumps) but less successful in adapting radically new technologies that disrupt incumbent flowsheets or processes.The installed power of grinding mills has increased linearly over the past 25 years (Meka & Lane, 2010) and pumps and classification equipment have kept pace. The autogenous grinding (AG) and semiautogenous grinding (SAG) mills displaced stage crushing as a dominant method of coarse rock breakage in many applications causing crusher manufactures to increase the capacity of cone crushers to meet the competitive demand.Examples of new comminution technology in the 20th and 21st centuries are the development and adoption of cyclone classification in the 1940s (Newtech, 2016), AG milling in the late 1950s, vertical grinding mills in the 1980s, high pressure grinding rolls (HPGRs) also in the 1980s and ultrafine milling technology in the 1990s (Meka & Lane, 2010)."

Jan 1, 2016

By Simon Strong, Tim Brown, Luis Ignacio Sanz Vivanco

"One of the most significant technical and practical challenges facing the tunnel construction team on the Legacy Way road tunnel project in Brisbane, Australia was how to erect the pre-stressed precast concrete slabs to form the smoke duct in the tunnel boring machine (TBM) tunnels. An essential part of the tunnel ventilation system, the smoke duct, extends the full length of the 4.6km long twin, two lane tunnels. The vast majority of the tunnels (approx. 4.3km) were constructed using two 12.4m diameter double shield TBMs. The refurbished Herrenknecht machines broke several world records on the way to completing the tunnel excavation works in just over nine months. With the excavation complete the focus turned to solving the complex civil tunnel fit out challenges. A key component of the civil fit out of the tunnels was constructing the smoke duct in the TBM tunnels which was designed as a precast solution. The slabs which each measure 8.62m long by 2.0m wide by 200mm thick and weigh close to 9 tonne need to be erected above cast in situ corbels whilst other tunnel finishing works continue. The space proofing clearance offered by the design to the support corbels below and the precast segmental lining above was in the order of only 100mm. This paper details the events of how the Transcity JV tunnel fit out team, comprising some of Europe and Australia’s leading tunnel construction specialists, drew upon the global strengths of the existing JV member companies and the global reach of leading TBM manufacturer Herrenknecht to develop an innovative system to solve this challenging problem. This globetrotting story, which starts in Australia, visits Europe and mainland China before returning to Brisbane where it all began."

Jan 1, 2016

By X. Song, Q. Zhang

"The development of fracture zones in surrounding rock mass has significant impact on the stability of underground mine roadways. Detection of the fracture zones is of compelling importance for maintaining roadway stability as well as for safe and speedy excavation of the roadways. This paper presents a study conducted at Dong Bao Wei underground coal mine, where the roadways were developed in diabase rock mass. The roadways suffered severe damages, including sloughing and excessive floor heaving. The borehole imaging technique was applied in the study to observe and detect fracture zone development surrounding the roadway openings. Based on the borehole imaging studies, new roadway support systems were proposed to improve the stability. INTRODUCTION At the Dong Bao Wei Coal Mine three main roadways of the west wing were excavated. The three roadways had semicircle arch cross sections and were at a depth of 650 meters, each being about 750 meters in length. The roadways were driven through a section of thick diabase intrusion, which was softened by water with reduced strength and may turn into powder form under weathering. Site investigation indicated that the roadways in diabase intrusion zone were badly damaged due to severe deformation, and very serious roadway sidewall sloughing and spalling accompanied by severe floor heave often occurred.(Figures 1 and 2) In order to ensure the normal use of the roadway, undercuts were excavated. However, this operation seriously affected the roadway construction progress and increased the amount of roadway support operations as well as the roadway maintenance costs. Furthermore, a roof fall accident occurred in nearby drilling site. The investigation indicated insufficient support provided for the roadways which imposed significant safety hazards and would have serious impact to mining production and subsequent mining activities.The support of the main roadways is a critical task and is the focus of the underground opening excavation work at the mine, since more than 40 years of service life is required from these main roadways. For these roadways, large cross sections with high degree of stability and minimal amount of deformation should be maintained. Therefore, providing sufficient and appropriate roadway supports is of significant importance to the coal mine. In this paper, in order to optimize the roadway supporting system, studies were carried out on the geological structures, lithological characters, roof bolt anchoring features and suitable anchoring layers. The studies were aimed at ensuring the stability of mine roadways, reducing the roadway maintenance costs and providing a safe mine passageway for orderly production and progressive development of the mine"

Jan 1, 2016

By J. Baumbach, H. Bombach, M. Stelter

"Today technical electro-refining processes for copper exclusively use sulfuric acid, for silver refining nitric acid electrolytes are used. Sulfuric acid is characterized by very good chemical and electrochemical stability, good conductivity and low cost. The disadvantages of sulfuric acid are the precipitation of fine-grained cathodes with smooth surfaces only by using additives like glue, thiourea and chloride. In case of silver the electrolyte is electrochemical unstable and bears the risk of the formation of toxic NOx when pH is too low. A second disadvantage is the form of electrodeposition of silver as dendrites with their removal from the bottom of the Möbius cells.This paper reports the results concerning the application of an alternative electrolyte in copper and silver electro-refining. At first the electrolyte was characterized by the determination of current density potential curves. Electrolysis experiments were performed in laboratory scale using technical anodes for copper and synthetic anodes for silver. During the copper tests the solubility of contaminations from the anodes and the amount and chemical composition of the anode slimes were determined. Moreover the influence of current density, electrolyte temperature and the effect of several additives on the precipitation and chemical purity of the cathodes were investigated. In all experiments cell voltage as well as anodic and cathodic polarization was measured and current efficiency and specific energy consumption were calculated. A comparison with the results with those of tests using conventional sulfuric acid electrolyte shows the advantages and disadvantages of both systems, additionally the technical application chances and limitations for the new electrolyte. This electrolyte enables the precipitation of smooth copper cathodes with low silver and sulfur concentrations even at lower temperatures without any additive. For silver refining the electrodeposition of compact silver sheets is possible, that can be stripped comparable to those in copper electro-refining."

Jan 1, 2016

By K. Ramji

"The development curve in the extractive sector has become longer, steeper, and riskier due to increased social, legal, and political risks from various stakeholders. Indigenous peoples are a unique stakeholder because their growing legal rights to lands and resources can often determine a project’s outcome. A project will only be successful if it is able to obtain the legal permits, withstand any judicial reviews, and gain and maintain the social license to operate. Stakeholder identification, management, and engagement are key risk-mitigation tools required to successfully convert risks into opportunities.RÉSUMÉ La courbe de développement du secteur de l’extraction s’est allongée, elle est devenue plus abrupte et plus hasardeuse en raison de l’accroissement des risques sociaux, légaux et politiques venant des divers intervenants. Les peuples autochtones sont des intervenants uniques puisque leurs droits légaux croissants sur les terres et les ressources déterminent souvent ce qu’il adviendra d’un projet. Un projet ne pourra réussir que s’il est capable d’obtenir les permis légaux, passer à travers les analyses judiciaires, puis obtenir et maintenir le permis social d’exploitation. L’identification des intervenants, la direction et l’engagement constituent les outils clés de l’atténuation des risques nécessaires pour bien convertir les risques en possibilités."

Jan 1, 2016

By Jean Wehbe, Daniel C. Brahana

"The new Mercedes-Benz Stadium (MBS), home of the Atlanta Falcons, is part of a new era of stadium construction in the U.S. These new-age stadiums are larger and have more amenities than their predecessors. Many of the MBS’s features, including its innovative retractable roof, result in extraordinary structural loads. The roof structure is supported by a series of mega columns that bear on eight large caps, six of which are supported by drilled piers. Each of the pier caps contains between 8 and 16 drilled piers that bear in the underlying bedrock. The design pier diameters are 6 and 6.5 ft (1.8 m and 1.9 m). Augercast piles were used to support two of the mega column caps. Drilled piers, augercast piles, aggregate piers and spread footings were used to support the more lightly loaded portions of the structure.The focus of this article is the construction aspects of the drilled pier foundations. Initially, a fairly extensive drilled pier load test program was performed. Load testing included a Statnamic compression test, two Osterberg Cell tests and two lateral tests. Production pier installation included over 3,800 linear ft (1,158.2 m) of earth excavation and over 1,350 linear ft (411.4 m) of hard rock excavation. The piers contain more than 6,600 cu yd (4,587.3 cu m) of concrete and 1,100 tons (998 tonnes) of reinforcing steel. Drilled pier installation took about 4.5 months. ABE Enterprises was the specialty foundation subcontractor and Bauer-Pileco was the equipment provider.Site and Subsurface ConditionsThe project site is in downtown Atlanta and was originally occupied by residential buildings. A portion of the site was later developed as a rail yard, and other areas contained light manufacturing, warehouses and other relatively light structures. For the past 15 to 20 years the site had been used for surface parking.Beneath a surficial layer of manmade fill, soil test borings at the site generally encountered residual soil, partially weathered rock and the parent bedrock. The bedrock at the site is highly variable, both in elevation and in hardness/quality. The depth to rock is reasonably uniform within the western two-thirds of the site at about 20 to 50 ft (6 to 15.2 m), with a few exceptions. In the eastern third of the site, the rock drops off dramatically to the north and east. In one mega column cap, there was almost 80 ft (24.3 m) in elevation difference. In two borings in the cap that were 20 ft (6.1 m) apart, the top of rock varied in elevation by 34 ft (10.3 m)"

Jan 1, 2016

By Pawan Bharadwaj, Wim Mulder, Thomas Tscharner, Guy Drijkoningen, Rob Jenneskens

"The Earth’s properties, composition and structure ahead of a tunnel boring machine (TBM) should be mapped for hazard assessment during excavation. We study the use of seismic-exploration techniques for this purpose. We focus on a seismic system for soft soils, where shear waves are better and easier to interpret than compressional waves, as has been shown over the last decade. The system is intended to be deployed on the machine’s cutter head, with a few seismic sources and sufficiently many seismic sensors to tackle spatial variability and noise characteristics. An important property of the newly developed system is its ability to process data with very little human interaction. Images need to be available in near real time, without human interactions slowing down the imaging process. This can be achieved by employing Full Waveform Inversion, which minimizes the difference between modeled and observed data. Because this method may suffer from local minima in the cost function if the data lack low-frequency information, we employ a dedicated seismic source that can generate sufficiently low frequencies for the relevant length scales. With data acquired in a number of field settings that mimic realistic TBM configurations, we show that the designed seismic system can successfully look ahead of the TBM and offers a valuable capability to support decision-making during tunnel excavation. INTRODUCTION While excavating a tunnel with a Tunnel Boring Machine (TBM), the geology and the ground conditions along the planned tunnel trajectory need to be investigated in order to safely and efficiently carry out the underground operations. This entails detecting the occurrence of boulders, foundations, pipes and faults, necessary to prevent hazards and time-consuming delays in the tunnel boring operations. In order to facilitate ground prediction ahead of a TBM, techniques as used in seismic exploration can be deployed. Two components common to seismic-exploration techniques are data acquisition and processing, the latter including inversion. We will discuss each of these for the application to tunnel excavation with TBM, in particular for soft soils."

Jan 1, 2016

By T. R. Ley

"RELIABILITY & SAFETY – TOGETHER. REALLY? I was starkly reminded of the challenges facing by the coal industry while talking with a number of senior mining executives. One said to me: “Safety is the #1 priority in our organization but of course, dollars are very, very important!!!” A coal mine worker at the Bluefield Coal Show claimed: “We know our equipment is bleeding hydraulic fluid all over the place but all that matters is getting the coal out”. We all understand. We want our people to go home safely at the end of the day but the coal industry is bleeding – fluids, dollars and real blood. An issue getting plenty of buzz these days is equipment reliability – in mining too! Achieving an optimal return from the massive investments in equipment is a critical requirement for success within a capital intensive industry like coal mining. You can cut costs by scrimping on maintenance, scavenging used parts and downsizing. Or, you can save money by being smarter with your asset management processes. Can we afford to spend money on both safety and reliability? Is one more important than the other? Many leading edge companies from a variety of industries will tell you that you can’t just cost-cut your way to profitability - or even survival. You need to systematically improve the effectiveness of your business. Do reliability and safety both have a place in improving the performance of the coal industry? According to Ron Moore, of The RM Group, the answer is emphatically YES! Ron says: “If you believe in safety, then you MUST believe in reliability and, more importantly, have the appropriate policies, systems, practices and measures in place. If you want lower costs, you must get your processes right. Simple cost cutting will remove resources from your system without changing the underlying system design, and performance will likely deteriorate.” Figure 1 shows the 5+ year results of a large manufacturing company. When plants are running well (high Asset Utilization), then injuries are less likely. Figure 2 plots data from a number of manufacturing plants. If you want sustainably lower costs get your reliability processes right. But these are manufacturing companies, not coal mining operations! It doesn’t matter. The fundamentals still apply. Mining industry thought leaders tell us that manufacturing is 20-30 years ahead of us and we need to learn from them – and do so quickly. Leading companies, no matter the industry, think in terms of operational excellence. They see this as the meshing of people, process and technology to achieve optimal results. Safety and reliability go hand-in-hand. People and equipment are different – but only to the extent that each requires its own relevant, but related, policies, practices, systems and metrics to achieve effective performance."

Jan 1, 2016

By M. C. Harris

"Excess Gibbs energy is a thermodynamic parameter which quantifies the difference between the value of the Gibbs energy for a real mixture and that for an ideal mixture. More specifically the partial molar excess Gibbs energy of a species (i) in a mixture is indicated by the change in the overall excess Gibbs energy of the solution as the number of moles of species (i) changes while keeping temperature, pressure and the number of moles of all other species in the solution constant. Generally it is obtained from the activity coefficient which in turn can be obtained for a species in a mixture using a variety of models. The most widely used method is to use UNIFAC. Flotation is probably the most important process in the concentration of minerals and requires the use of reagents such as collectors and frothers. There is abundant experimental data which illustrates that collectors of different alkyl chain lengths will change the contact angle and that frothers of different structures and molecular weights will result in changes in key flotation properties such as froth behavior, surface tension and critical coalescence concentration. In this paper it is shown that there is a strong linear relationship between measured parameters such as froth volume/height, surface tension, critical coalescence concentration and contact angle and the partial molar excess Gibbs energy of the molecules used. Proposals are made to explain these correlations.INTRODUCTIONAs is well known froth flotation is arguably the most widely used process in the separation of minerals. In broad terms the process relies on the use of reagents known as collectors to adsorb onto a mineral surface and thus render the mineral particle hydrophobic. Alkyl thiolates are very commonly used for this purpose. The hydrophobicity is induced as a result of the alkyl group’s molecular structural properties which results in it forming a non-ideal mixture with the process water. Surfactants (or frothers) are typically alcohols and are known to lower the surface tension of the system and also inhibit bubble coalescence and reduce bubble size. Since alcohols are polar they will also form a non-ideal mixture with water. The hydrophobic mineral attaches to the bubble and rises to the froth phase where the valuable mineral is recovered as a concentrate. Frothers have often been characterized using the so-called HLB (hydrophobic-lipophilic balance) number but recently it was shown that the use of activity coefficients (?) or excess Gibbs energy (G ex ), which is calculated using equation (1) is a much more appropriate way to describe the behavior of these reagents in non-ideal mixtures with water (Corin and O’Connor, 2014)."

Jan 1, 2016

By Saeed Zandi, Kazem Oraee

"Tunnels and galleries are the most important structures in coal mines. They are used for variety of purposes, such as transporting ore and people and for ventilation. A well-designed support system is necessary to stabilize structures and prevent collapse.Using rock bolts increases the strength of the rock in which tunnels are made. Rock bolts are used extensively in most underground mines today, and coal mines are no exception. Almost all galleries in a typical coal mine use some type of rock bolt, at least, as a means of partial or supplementary support.In this research, changing the support system from expensive methods to the use of rock bolts as the primary means of support is discussed, with the focus on a particular gallery in Hejdak coal mine. Visionary design methods, in conjunction with rock mass classification schedules, were used to determine an optimal rock bolt pattern. For this purpose, rock mass rating (RlVIR) and quality index (Q) classification systems were used. Several empirical methods were also used to design an optimal pattern for rock bolt installation in the particular tunnel under analysis.As such, the tunnel support system was designed using both finite element and empirical methods. Finally, the results obtained from both numerical and empirical methods were compared under different load conditions. The methodology prescribed in this paper, together with the comparison, can be a useful tool when selecting a support system. The results can also be used to design a support system in this and any other coal mine with similar conditions.INTRODUCTIONSince the advent of underground excavation techniques, one of the biggest challenges has been stabilizing tunnel walls and preventing roof collapse in tunnels and other underground openings, such as galleries. Loose rocks and layers drop into tunnels and galleries, except in very hard rock. Underground roof collapse and falling rocks can have devastating effects on the safety of operation personnel and equipment and can seriously affect production. When designing an underground coal mine, the stability of tunnels and galleries is an important parameter that should be studied carefully because it has an important role in the production process of the mine. Therefore, an appropriate and well-designed support system is necessary for preventing collapse and helping to stabilize the tunnels and galleries."

Jan 1, 2016

By Ming-yi Zhang, Zhong-nian Yang, Xiao-ming Guan, Quan-wei Liu

"In slurry balanced shield tunneling, how to ensure the safety of construction and to reduce the influence on the environment has arisen wide attention of scholars both at home and abroad. But now it is still in the stage of experience as to the instability mechanism of the slurry shield tunneling excavation and its stability analysis. Based on the large-diameter model tests and FLAC 3D, the effect of the different waterhead (non-water, 0.9m and 1.1m) on stability of excavation face of slurry balanced shield is investigated, and the stability mechanics is proposed. The results show that: waterhead heights play an important role on excavation face instability features of slurry balanced shield in sandy stratum, Regarding the different waterhead heights, the development mode of the excavation face instability features can be divided into non-water mode, lower-waterhead mode and higher-waterhead mode; soil arching is existed in the process of excavation face instability, the settlement of ground lags behind excavation face failure, the soil arching will block or eliminate the effects of ground settlement; excess pore water pressure need to be considered besides earth pressure and hydrostatic pressure when the supporting force is calculated. INTRODUCTION With the development of the society, for the cities all over the world, the exploitation of underground space has become an important measure to solve the problems about population, resources and environment and an important way to heal the city syndrome and implement the sustainable development strategy of city. Constructing shield tunnel with large diameter is the major trend for development of tunnel construction (Yin, 1999). Instability of excavation face caused by relief of shield soil stress is still one problem that needs to be solved (Xiang, 2001). How to reduce the effects of construction on surrounding environment? How to accurately determine the instability of shield excavation face and to effectively and reasonably select the supporting force? These are the crucial problems which need to be solved during shield construction."

Jan 1, 2016

By D. Vogt

"Rock has been cut in the process of mining since before the invention of explosives. Today, we seek to return to cutting to reap the benefits of continuous operations for South African underground hard-rock mines, to improve speed of access to the orebody, and to improve the efficiency of mining operations.Development of new technology fits within a framework of engineering knowledge. By understanding the characteristics of the rock, the tools we use to cut it with, and the history of mining and rock cutting, we can see the genesis of the road-header, the longwall, and the continuous miner, all drag bit cutters. They have emerged as the solutions of choice for underground mining of softer materials such as coal and potash. In hard rock, the challenges are the forces required to break the rock, and the wear of the tools caused by the rock’s abrasiveness. Only disc cutters currently handle the challenges, and even then, often not economically. New materials like thermally stable diamond composite will help, as will combinations of mechanical cutters and other methods such as high-pressure water or high temperatures.It is not clear what will emerge as the consensus technique for hardrock cutting. Experience teaches that development is expensive and the market is small. Will mining companies partner with equipment developers to make the technological leap? Or will the solution come from a systems approach, not considered here?IntroductionBlasting is the dominant method of breaking rock for the purposes of mining. When used underground, blasting is part of a batch process. If rock can be cut rather than blasted, mining can become continuous, leading to process and efficiency improvements.Coal produced from underground mines is now predominantly excavated using mechanical means, but underground hard rock is still broken primarily by explosives.This paper traces the history of rock cutting, reviews the main physical processes that are or could be used, and comments on the future. It is written from the perspective of narrow-stope hard-rock mining typical of South African gold and platinum mines."

Jan 1, 2016

By V. O. Tenorio, A. M. Sanzana

"INTRODUCTION This report summarizes a research about mines which are transitioning from surface to underground mines. It is a guide to make strategic decision in these increasing amount of mines. Capital and operating costs are linked with major strategic decisions in the exploitation of an ore body. This is the reason to analyze costs related to this transitioning world trend. There are multiple reasons for transitioning from Open-Pit (OP) to Underground (UG) mining. The primary economic incentive for going UG is that the cost per unit of ore from OP mining eventually exceeds that from UG extraction. This is due to the excessive amount of waste that must be extracted when the depth of the pit increases. In addition, the reduced footprint of UG operations contributes to diminish the environmental impact on the surface. Furthermore, it becomes more difficult to find new, easily accessible ore deposits. Then, a cost model helps to guide strategic decisions in the transition from OP-to-UG mines. Objectives • Propose a methodology to guide strategic decisions in the transition from OP to UG mining. • Create an integrated cost model based on existing OP and UG individual cases. • Identify and characterize a group of mines transitioning from OP to UG. • Analyze operating and capital costs of a particular transitioning from OP to UG mine. MAIN CONCEPTS Open Pit Mining (OP) The main decisions in OP mines are: Cut-off grade, Stripping Ratio (SR), equipment size, stockpiling, pushback sequencing and processing capacity. The stripping ratio is measured as the tonnage of waste required to be removed to reach and extract one tonne of ore. The material extracted from an OP exploitation can be classified as waste and ore. This classification depends on the cut-off grade. The cut-off grade indicates the minimum amount of material with economic value in a block. The waste from the mine is going to the waste dump and the ore is going to stockpiles where will be store and then going to the processing plant (leaching or concentrator). The waste of this process is going to the tailing pond big pools. And the product is sell in the market. Another important issue is the mining capacity which is going to define the investment in mining equipment. Underground Mining (UG) The first decision to be made in order to open an underground mine is selecting the mining method. Caving methods are the more productive and have lower operating costs. There are three caving methods: Block Caving (BC), Panel Caving (BC) and Sublevel Caving (BC). The access development could be an horizontal adit or a straight or downspiral decline. A shaft could be used for inclined or vertical access. Other key issues are: equipment capacity, cut-off grade and production sequencing."

Jan 1, 2016

"Block caving is the preferred underground mining method to profitably extract massive, low-grade orebodies; however, lack of cave access inhibits understanding the rockmass response to mining, which is needed for safer, more productive operations. Combining large datasets from multiple sources with virtual reality scientific visualization (VRSV) is an alternative method for understanding complex cave behaviour, by providing virtual access to the cave. A customized VRSV module was developed at UNSW Australia to investigate rockmass response to undercut developments at a case-study block caving operation. Time/sequence effects are investigated in rockmass response to blasting, which is an important factor in hard-rock mines.RÉSUMÉ La méthode d’extraction souterraine par blocs foudroyés est la méthode préférentielle pour extraire rentablement des gisements massifs à faible teneur. Toutefois, le manque d’accès à la chambre restreint la compréhension de la réponse de la masse rocheuse à l’exploitation, ce qui est nécessaire pour obtenir des opérations plus sécuritaires et plus productives. La combinaison de grands ensembles de données de multiples sources avec la visualisation scientifique par réalité virtuelle (VRSV) constitue un autre moyen de comprendre le comportement complexe de la chambre en fournissant un accès virtuel à la chambre. Un module de VRSV sur mesure a été développé à l’Université de Nouvelles-Galles du Sud (UNSW) en Australie afin d’étudier, dans une étude de cas d’une exploitation par blocs foudroyés, la réponse de la masse rocheuse aux développements de galeries de sous-cavage. Les effets de temps/séquence sont étudiés dans la réponse de la masse rocheuse au sautage, ce qui est un facteur important dans les mines de roches dures."

Jan 1, 2016